Search results for: roughness tester
443 Experimental Investigation on Sustainable Machining of Hastelloy C-276 Utilizing Different Cooling Strategies
Authors: Balkar Singh, Gurpreet Singh, Vivek Aggarwal, Sehijpal Singh
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The present research focused to improve the machinability of Hastelloy C-276 at different machining speeds such as 31, 55, and 79 m/min. The use of CO2 gas and Minimum quantity lubrication (MQL) was applied as coolant and lubrication purposes to enhance the machinability of the superalloy. The output in the form of surface roughness (S.R) and heat generation was monitored under dry, MQL, and MQL-CO2-cooled conditions. The Design of the Experiment was prepared using MINITAB software utilizing Taguchi L-27 orthogonal arrays followed by ANOVA analysis for finding the impact of input variables on output responses. At different speeds and lubrication conditions, different behavioral patterns for Surface Roughness and the temperature was observed. ANOVA analysis depicted that the cooling environment impacted the S.R. majorly (50%) followed by cutting speed (29.84%), feed rate (5.09%), and least through depth of cut (4.95%). On the other side, the temperature was greatly influenced by cutting speed (69.12%), Cryo-MQL (8.09%), feed rate (7.59%), and depth of cut (6.20%). Experimental results revealed that Cryo-MQL cooling enhanced the Surface roughness by 12% compared to MQL condition.Keywords: Hastelloy C-276, minimum quantity lubrication, olive oil, cryogenic Cooling (CO2)
Procedia PDF Downloads 132442 Modification and Surface Characterization of the Co20Cr15W10Ni Alloy for Application as Biomaterial
Authors: Fernanda A. Vechietti, Natália O. B. Muniz, Laura C. Treccani, Kurosch. Rezwan, Luis Alberto dos Santos
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CoCr alloys are widely used in prosthetic implants due to their excellent mechanical properties, such as good tensile strength, elastic modulus and wear resistance. Their biocompatibility and lack of corrosion are also prominent features of this alloy. One of the most effective and simple ways to protect metal’s surfaces are treatments, such as electrochemical oxidation by passivation, which is used as a protect release of metallic ions. Another useful treatment is the electropolishing, which is used to reduce the carbide concentration and protrusion at the implanted surface. Electropolishing is a cheap and effective method for treatment of implants, which generally has complex geometries. The purpose of this study is surface modification of the alloy CoCr(ASTM F90-09) by different methods: polishing, electro polishing, passivation and heat treatment for application as biomaterials. The modification of the surface was studied and characterized by SEM, profilometry, wettability and compared to the surface of the samples untreated. The heat treatment and of passivation increased roughness (0.477 µm and 0.825 µm) the samples in relation the sample electropolished and polished(0.131 µm and 0.274 µm) and were observed the improve wettability’s with the increase the roughness.Keywords: biomaterial, CoCr, surface treatment, heat treatment, roughness
Procedia PDF Downloads 535441 Surface Topography Measurement by Confocal Spectral Interferometry
Authors: A. Manallah, C. Meier
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Confocal spectral interferometry (CSI) is an innovative optical method for determining microtopography of surfaces and thickness of transparent layers, based on the combination of two optical principles: confocal imaging, and spectral interferometry. Confocal optical system images at each instant a single point of the sample. The whole surface is reconstructed by plan scanning. The interference signal generated by mixing two white-light beams is analyzed using a spectrometer. In this work, five ‘rugotests’ of known standard roughnesses are investigated. The topography is then measured and illustrated, and the equivalent roughness is determined and compared with the standard values.Keywords: confocal spectral interferometry, nondestructive testing, optical metrology, surface topography, roughness
Procedia PDF Downloads 265440 Influence of Counter-Face Roughness on the Friction of Bionic Microstructures
Authors: Haytam Kasem
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The problem of quick and easy reversible attachment has become of great importance in different fields of technology. For the reason, during the last decade, a new emerging field of adhesion science has been developed. Essentially inspired by some animals and insects, which during their natural evolution have developed fantastic biological attachment systems allowing them to adhere and run on walls and ceilings of uneven surfaces. Potential applications of engineering bio-inspired solutions include climbing robots, handling systems for wafers in nanofabrication facilities, and mobile sensor platforms, to name a few. However, despite the efforts provided to apply bio-inspired patterned adhesive-surfaces to the biomedical field, they are still in the early stages compared with their conventional uses in other industries mentioned above. In fact, there are some critical issues that still need to be addressed for the wide usage of the bio-inspired patterned surfaces as advanced biomedical platforms. For example, surface durability and long-term stability of surfaces with high adhesive capacity should be improved, but also the friction and adhesion capacities of these bio-inspired microstructures when contacting rough surfaces. One of the well-known prototypes for bio-inspired attachment systems is biomimetic wall-shaped hierarchical microstructure for gecko-like attachments. Although physical background of these attachment systems is widely understood, the influence of counter-face roughness and its relationship with the friction force generated when sliding against wall-shaped hierarchical microstructure have yet to be fully analyzed and understood. To elucidate the effect of the counter-face roughness on the friction of biomimetic wall-shaped hierarchical microstructure we have replicated the isotropic topography of 12 different surfaces using replicas made of the same epoxy material. The different counter-faces were fully characterized under 3D optical profilometer to measure roughness parameters. The friction forces generated by spatula-shaped microstructure in contact with the tested counter-faces were measured on a home-made tribometer and compared with the friction forces generated by the spatulae in contact with a smooth reference. It was found that classical roughness parameters, such as average roughness Ra and others, could not be utilized to explain topography-related variation in friction force. This has led us to the development of an integrated roughness parameter obtained by combining different parameters which are the mean asperity radius of curvature (R), the asperity density (η), the deviation of asperities high (σ) and the mean asperities angle (SDQ). This new integrated parameter is capable of explaining the variation of results of friction measurements. Based on the experimental results, we developed and validated an analytical model to predict the variation of the friction force as a function of roughness parameters of the counter-face and the applied normal load, as well.Keywords: friction, bio-mimetic micro-structure, counter-face roughness, analytical model
Procedia PDF Downloads 232439 Effects of Milling Process Parameters on Cutting Forces and Surface Roughness When Finishing Ti6al4v Produced by Electron Beam Melting
Authors: Abdulmajeed Dabwan, Saqib Anwar, Ali Al-Samhan
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Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.Keywords: electron beam melting, additive manufacturing, Ti6Al4V, surface morphology
Procedia PDF Downloads 107438 Taguchi-Based Surface Roughness Optimization for Slotted and Tapered Cylindrical Products in Milling and Turning Operations
Authors: Vineeth G. Kuriakose, Joseph C. Chen, Ye Li
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The research follows a systematic approach to optimize the parameters for parts machined by turning and milling processes. The quality characteristic chosen is surface roughness since the surface finish plays an important role for parts that require surface contact. A tapered cylindrical surface is designed as a test specimen for the research. The material chosen for machining is aluminum alloy 6061 due to its wide variety of industrial and engineering applications. HAAS VF-2 TR computer numerical control (CNC) vertical machining center is used for milling and HAAS ST-20 CNC machine is used for turning in this research. Taguchi analysis is used to optimize the surface roughness of the machined parts. The L9 Orthogonal Array is designed for four controllable factors with three different levels each, resulting in 18 experimental runs. Signal to Noise (S/N) Ratio is calculated for achieving the specific target value of 75 ± 15 µin. The controllable parameters chosen for turning process are feed rate, depth of cut, coolant flow and finish cut and for milling process are feed rate, spindle speed, step over and coolant flow. The uncontrollable factors are tool geometry for turning process and tool material for milling process. Hypothesis testing is conducted to study the significance of different uncontrollable factors on the surface roughnesses. The optimal parameter settings were identified from the Taguchi analysis and the process capability Cp and the process capability index Cpk were improved from 1.76 and 0.02 to 3.70 and 2.10 respectively for turning process and from 0.87 and 0.19 to 3.85 and 2.70 respectively for the milling process. The surface roughnesses were improved from 60.17 µin to 68.50 µin, reducing the defect rate from 52.39% to 0% for the turning process and from 93.18 µin to 79.49 µin, reducing the defect rate from 71.23% to 0% for the milling process. The purpose of this study is to efficiently utilize the Taguchi design analysis to improve the surface roughness.Keywords: surface roughness, Taguchi parameter design, CNC turning, CNC milling
Procedia PDF Downloads 146437 Surface Modification of Polycarbonate Substrates via Direct Fluorination to Promote the Staining with Methylene Blue
Authors: Haruka Kaji, Jae-Ho Kim, Yonezawa Susumu
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The surface of polycarbonate (PC) was modified with fluorine gas at 25℃ and 10-380 Torr for one h. The surface roughness of the fluorinated PC samples was approximately five times larger than that (1.2 nm) of the untreated thing. The results of Fourier transform infrared spectroscopy, and X-ray photoelectron spectroscopy showed that the bonds (e.g., -C=O and C-Hx) derived from raw PC decreased and were converted into fluorinated bonds (e.g., -CFx) after surface fluorination. These fluorinated bonds showed higher electronegativity according to the zeta potential results. Fluorinated PC could be strained with the methylene blue basic dye because of the increased surface roughness and the negatively charged surface.Keywords: dyeable layer, polycarbonate, surface fluorination, zeta potential
Procedia PDF Downloads 167436 Thermohydraulic Performance Comparison of Artificially Roughened Rectangular Channels
Authors: Narender Singh Thakur, Sunil Chamoli
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The use of roughness geometry in the rectangular channel duct is an effective technique to enhance the rate of heat transfer to the working fluid. The present research concentrates on the performance comparison of a rectangular channel with different roughness geometry of the test plate. The performance enhancement is compared by considering the statistical correlations developed by the various investigators for Nusselt number and friction factor. Among all the investigated geometries multiple v-shaped rib roughened rectangular channel found thermo hydraulically better than other investigated geometries under similar current and operating conditions.Keywords: nusselt number, friction factor, thermohydraulic, performance parameter
Procedia PDF Downloads 408435 Sensitivity Analysis of Movable Bed Roughness Formula in Sandy Rivers
Authors: Mehdi Fuladipanah
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Sensitivity analysis as a technique is applied to determine influential input factors on model output. Variance-based sensitivity analysis method has more application compared to other methods because of including linear and non-linear models. In this paper, van Rijn’s movable bed roughness formula was selected to evaluate because of its reasonable results in sandy rivers. This equation contains four variables as: flow depth, sediment size,bBed form height and bed form length. These variable’s importance was determined using the first order of Fourier Amplitude Sensitivity Test. Sensitivity index was applied to evaluate importance of factors. The first order FAST based sensitivity indices test, explain 90% of the total variance that is indicating acceptance criteria of FAST application. More value of this index is indicating more important variable. Results show that bed form height, bed form length, sediment size and flow depth are more influential factors with sensitivity index: 32%, 24%, 19% and 15% respectively.Keywords: sdensitivity analysis, variance, movable bed roughness formula, Sandy River
Procedia PDF Downloads 254434 Morphological and Optical Properties of (Al, In) Doped ZnO Thin Films Textured (103) by Sol-Gel Method
Authors: S. Benzitouni, M. Zaabat, A. Mahdjoub, A. Benaboud, T.Saidani
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To improve the physical properties of ZnO nanostructures textured (103) by sol-gel dip coating method, Al and In are used as dopant with different weight ratios (5%, 10%). The comparative study between Al doped ZnO thin films (AZO) and In doped ZnO (IZO) are made by different analysis technic. XRD showed that the films are Pollycristallins with hexagonal wûrtzite structure and preferred orientation (002) and (103). UV-Vis spectroscopy showed that all films have a high transmission (> 85%); the interference fringes are only observed for IZO. The optical gap is reduced due to the introduction of In (minimum value is 3.12 eV), but increased in the presence of Al (maximum value is 3.34 eV). The thickness of the layers was obtained by modeling (using Forouhi Bloomer method). AFM used to observe the surface texture of the films and determined grain size and surface roughness (RMS) which varies in a small range [3.14 to 1.25] nm.Keywords: ZnO, optical gap, roughness (RMS), nanostructures
Procedia PDF Downloads 320433 Influence of 3D Printing Parameters on Surface Finish of Ceramic Hip Prostheses Fixed by Means of Osteointegration
Authors: Irene Buj-Corral, Ali Bagheri, Alejandro Dominguez-Fernandez
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In recent years, use of ceramic prostheses as an implant in some parts of body has become common. In the present study, research has focused on replacement of the acetabulum bone, which is a part of the pelvis bone. Metallic prostheses have shown some problems such as release of metal ions into patient's blood. In addition, fracture of liners and squeezing between surface of femoral head and inner surface of acetabulum have been reported. Ceramic prostheses have the advantage of low debris and high strength, although they are more difficult to be manufactured than metallic ones. Specifically, new designs try to attempt an acetabulum in which the outer surface will be porous for proliferation of cells and fixation of the prostheses by means of osteointegration, while inner surface must be smooth enough to assure that the movement between femoral head and inner surface will be carried out with on feasibility. In the present study, 3D printing technologies are used for manufacturing ceramic prostheses. In Fused Deposition Modelling (FDM) process, 3D printed plastic prostheses are obtained by means of melting of a plastic filament and subsequent deposition on a glass surface. A similar process is applied to ceramics in which ceramic powders need to be mixed with a liquid polymer before depositing them. After 3D printing, parts are subjected to a sintering process in an oven so that they can achieve final strength. In the present paper, influence of printing parameters on surface roughness 3D printed ceramic parts are presented. Three parameter full factorial design of experiments was used. Selected variables were layer height, infill and nozzle diameter. Responses were average roughness Ra and mean roughness depth Rz. Regression analysis was applied to responses in order to obtain mathematical models for responses. Results showed that surface roughness depends mainly on layer height and nozzle diameter employed, while infill was found not to be significant. In order to get low surface roughness, low layer height and low infill should be selected. As a conclusion, layer height and infill are important parameters for obtaining good surface finish in ceramic 3D printed prostheses. However, use of too low infill could lead to prostheses with low mechanical strength. Such prostheses could not be able to bear the static and dynamic charges to which they are subjected once they are implanted in the body. This issue will be addressed in further research.Keywords: ceramic, hip prostheses, surface roughness, 3D printing
Procedia PDF Downloads 191432 Optical and Surface Characteristics of Direct Composite, Polished and Glazed Ceramic Materials After Exposure to Tooth Brush Abrasion and Staining Solution
Authors: Maryam Firouzmandi, Moosa Miri
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Aim and background: esthetic and structural reconstruction of anterior teeth may require the application of different restoration material. In this regard combination of direct composite veneer and ceramic crown is a common treatment option. Despite the initial matching, their long term harmony in term of optical and surface characteristics is a matter of concern. The purpose of this study is to evaluate and compare optical and surface characteristic of direct composite polished and glazed ceramic materials after exposure to tooth brush abrasion and staining solution. Materials and Methods: ten 2 mm thick disk shape specimens were prepared from IPS empress direct composite and twenty specimens from IPS e.max CAD blocks. Composite specimens and ten ceramic specimens were polished by using D&Z composite and ceramic polishing kit. The other ten specimens of ceramic were glazed with glazing liquid. Baseline measurement of roughness, CIElab coordinate, and luminance were recorded. Then the specimens underwent thermocycling, tooth brushing, and coffee staining. Afterword, the final measurements were recorded. Color coordinate were used to calculate ΔE76, ΔE00, translucency parameter, and contrast ratio. Data were analyzed by One-way ANOVA and post hoc LSD test. Results: baseline and final roughness of the study group were not different. At baseline, the order of roughness for the study group were as follows: composite < glazed ceramic < polished ceramic, but after aging, no difference. Between ceramic groups was not detected. The comparison of baseline and final luminance was similar to roughness but in reverse order. Unlike differential roughness which was comparable between the groups, changes in luminance of the glazed ceramic group was higher than other groups. ΔE76 and ΔE00 in the composite group were 18.35 and 12.84, in the glazed ceramic group were 1.3 and 0.79, and in polished ceramic were 1.26 and 0.85. These values for the composite group were significantly different from ceramic groups. Translucency of composite at baseline was significantly higher than final, but there was no significant difference between these values in ceramic groups. Composite was more translucency than ceramic at baseline and final measurement. Conclusion: Glazed ceramic surface was smoother than polished ceramic. Aging did not change the roughness. Optical properties (color and translucency) of the composite were influenced by aging. Luminance of composite, glazed ceramic, and polished ceramic decreased after aging, but the reduction in glazed ceramic was more pronounced.Keywords: ceramic, tooth-brush abrasion, staining solution, composite resin
Procedia PDF Downloads 175431 Experimental Study Analyzing the Similarity Theory Formulations for the Effect of Aerodynamic Roughness Length on Turbulence Length Scales in the Atmospheric Surface Layer
Authors: Matthew J. Emes, Azadeh Jafari, Maziar Arjomandi
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Velocity fluctuations of shear-generated turbulence are largest in the atmospheric surface layer (ASL) of nominal 100 m depth, which can lead to dynamic effects such as galloping and flutter on small physical structures on the ground when the turbulence length scales and characteristic length of the physical structure are the same order of magnitude. Turbulence length scales are a measure of the average sizes of the energy-containing eddies that are widely estimated using two-point cross-correlation analysis to convert the temporal lag to a separation distance using Taylor’s hypothesis that the convection velocity is equal to the mean velocity at the corresponding height. Profiles of turbulence length scales in the neutrally-stratified ASL, as predicted by Monin-Obukhov similarity theory in Engineering Sciences Data Unit (ESDU) 85020 for single-point data and ESDU 86010 for two-point correlations, are largely dependent on the aerodynamic roughness length. Field measurements have shown that longitudinal turbulence length scales show significant regional variation, whereas length scales of the vertical component show consistent Obukhov scaling from site to site because of the absence of low-frequency components. Hence, the objective of this experimental study is to compare the similarity theory relationships between the turbulence length scales and aerodynamic roughness length with those calculated using the autocorrelations and cross-correlations of field measurement velocity data at two sites: the Surface Layer Turbulence and Environmental Science Test (SLTEST) facility in a desert ASL in Dugway, Utah, USA and the Commonwealth Scientific and Industrial Research Organisation (CSIRO) wind tower in a rural ASL in Jemalong, NSW, Australia. The results indicate that the longitudinal turbulence length scales increase with increasing aerodynamic roughness length, as opposed to the relationships derived by similarity theory correlations in ESDU models. However, the ratio of the turbulence length scales in the lateral and vertical directions to the longitudinal length scales is relatively independent of surface roughness, showing consistent inner-scaling between the two sites and the ESDU correlations. Further, the diurnal variation of wind velocity due to changes in atmospheric stability conditions has a significant effect on the turbulence structure of the energy-containing eddies in the lower ASL.Keywords: aerodynamic roughness length, atmospheric surface layer, similarity theory, turbulence length scales
Procedia PDF Downloads 120430 Development of Fuzzy Logic and Neuro-Fuzzy Surface Roughness Prediction Systems Coupled with Cutting Current in Milling Operation
Authors: Joseph C. Chen, Venkata Mohan Kudapa
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Development of two real-time surface roughness (Ra) prediction systems for milling operations was attempted. The systems used not only cutting parameters, such as feed rate and spindle speed, but also the cutting current generated and corrected by a clamp type energy sensor. Two different approaches were developed. First, a fuzzy inference system (FIS), in which the fuzzy logic rules are generated by experts in the milling processes, was used to conduct prediction modeling using current cutting data. Second, a neuro-fuzzy system (ANFIS) was explored. Neuro-fuzzy systems are adaptive techniques in which data are collected on the network, processed, and rules are generated by the system. The inference system then uses these rules to predict Ra as the output. Experimental results showed that the parameters of spindle speed, feed rate, depth of cut, and input current variation could predict Ra. These two systems enable the prediction of Ra during the milling operation with an average of 91.83% and 94.48% accuracy by FIS and ANFIS systems, respectively. Statistically, the ANFIS system provided better prediction accuracy than that of the FIS system.Keywords: surface roughness, input current, fuzzy logic, neuro-fuzzy, milling operations
Procedia PDF Downloads 131429 Magnetic Field Induced Tribological Properties of Magnetic Fluid
Authors: Kinjal Trivedi, Ramesh V. Upadhyay
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Magnetic fluid as a nanolubricant is a most recent field of study due to its unusual properties that can be tuned by applying a magnetic field. In present work, four ball tester has been used to investigate the tribological properties of the magnetic fluid having a 4 wt% of nanoparticles. The structural characterization of fluid shows crystallite size of particle is 11.7 nm and particles are nearly spherical in nature. The magnetic characterization shows the fluid saturation magnetization is 2.2 kA/m. The magnetic field applied using permanent strip magnet (0 to 1.6 mT) on the faces of the lock nut and fixing a solenoid (0 to 50 mT) around a shaft, such that shaft rotates freely. The magnetic flux line for both the systems analyzed using finite elemental analysis. The coefficient of friction increases with the application of magnetic field using permanent strip magnet compared to zero field value. While for the solenoid, it decreases at 20 mT. The wear scar diameter is lower for 1.1 mT and 20 mT when the magnetic field applied using permanent strip magnet and solenoid, respectively. The coefficient of friction and wear scar reduced by 29 % and 7 % at 20 mT using solenoid. The worn surface analysis carried out using Scanning Electron Microscope and Atomic Force Microscope to understand the wear mechanism. The results are explained on the basis of structure formation in a magnetic fluid upon application of magnetic field. It is concluded that the tribological properties of magnetic fluid depend on magnetic field and its applied direction.Keywords: four ball tester, magnetic fluid, nanolubricant, tribology
Procedia PDF Downloads 227428 Evaluation of Surface Roughness Condition Using App Roadroid
Authors: Diego de Almeida Pereira
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The roughness index of a road is considered the most important parameter about the quality of the pavement, as it has a close relation with the comfort and safety of the road users. Such condition can be established by means of functional evaluation of pavement surface deviations, measured by the International Roughness Index (IRI), an index that came out of the international evaluation of pavements, coordinated by the World Bank, and currently owns, as an index of limit measure, for purposes of receiving roads in Brazil, the value of 2.7 m/km. This work make use of the e.IRI parameter, obtained by the Roadroid app. for smartphones which use Android operating system. The choice of such application is due to the practicality for the user interaction, as it possesses a data storage on a cloud of its own, and the support given to universities all around the world. Data has been collected for six months, once in each month. The studies begun in March 2018, season of precipitations that worsen the conditions of the roads, besides the opportunity to accompany the damage and the quality of the interventions performed. About 350 kilometers of sections of four federal highways were analyzed, BR-020, BR-040, BR-060 and BR-070 that connect the Federal District (area where Brasilia is located) and surroundings, chosen for their economic and tourist importance, been two of them of federal and two others of private exploitation. As well as much of the road network, the analyzed stretches are coated of Hot Mix Asphalt (HMA). Thus, this present research performs a contrastive discussion between comfort conditions and safety of the roads under private exploitation in which users pay a fee to the concessionaires so they could travel on a road that meet the minimum requirements for usage, and regarding the quality of offered service on the roads under Federal Government jurisdiction. And finally, the contrast of data collected by National Department of Transport Infrastructure – DNIT, by means of a laser perfilometer, with data achieved by Roadroid, checking the applicability, the practicality and cost-effective, considering the app limitations.Keywords: roadroid, international roughness index, Brazilian roads, pavement
Procedia PDF Downloads 77427 Effects of Canned Cycles and Cutting Parameters on Hole Quality in Cryogenic Drilling of Aluminum 6061-6T
Authors: M. N. Islam, B. Boswell, Y. R. Ginting
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The influence of canned cycles and cutting parameters on hole quality in cryogenic drilling has been investigated experimentally and analytically. A three-level, three-parameter experiment was conducted by using the design-of-experiment methodology. The three levels of independent input parameters were the following: for canned cycles—a chip-breaking canned cycle (G73), a spot drilling canned cycle (G81), and a deep hole canned cycle (G83); for feed rates—0.2, 0.3, and 0.4 mm/rev; and for cutting speeds—60, 75, and 100 m/min. The selected work and tool materials were aluminum 6061-6T and high-speed steel (HSS), respectively. For cryogenic cooling, liquid nitrogen (LN2) was used and was applied externally. The measured output parameters were the three widely used quality characteristics of drilled holes—diameter error, circularity, and surface roughness. Pareto ANOVA was applied for analyzing the results. The findings revealed that the canned cycle has a significant effect on diameter error (contribution ratio 44.09%) and small effects on circularity and surface finish (contribution ratio 7.25% and 6.60%, respectively). The best results for the dimensional accuracy and surface roughness were achieved by G81. G73 produced the best circularity results; however, for dimensional accuracy, it was the worst level.Keywords: circularity, diameter error, drilling canned cycle, pareto ANOVA, surface roughness
Procedia PDF Downloads 278426 Comparison of Two-Phase Critical Flow Models for Estimation of Leak Flow Rate through Cracks
Authors: Tadashi Watanabe, Jinya Katsuyama, Akihiro Mano
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The estimation of leak flow rates through narrow cracks in structures is of importance for nuclear reactor safety, since the leak flow could be detected before occurrence of loss-of-coolant accidents. The two-phase critical leak flow rates are calculated using the system analysis code, and two representative non-homogeneous critical flow models, Henry-Fauske model and Ransom-Trapp model, are compared. The pressure decrease and vapor generation in the crack, and the leak flow rates are found to be larger for the Henry-Fauske model. It is shown that the leak flow rates are not affected by the structural temperature, but affected largely by the roughness of crack surface.Keywords: crack, critical flow, leak, roughness
Procedia PDF Downloads 168425 Active Part of the Burnishing Tool Effect on the Physico-Geometric Aspect of the Superficial Layer of 100C6 and 16NC6 Steels
Authors: Tarek Litim, Ouahiba Taamallah
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Burnishing is a mechanical surface treatment that combines several beneficial effects on the two steel grades studied. The application of burnishing to the ball or to the tip favors a better roughness compared to turning. In addition, it allows the consolidation of the surface layers through work hardening phenomena. The optimal effects are closely related to the treatment parameters and the active part of the device. With an improvement of 78% on the roughness, burnishing can be defined as a finishing operation in the machining range. With a 44% gain in consolidation rate, this treatment is an effective process for material consolidation. These effects are affected by several factors. The factors V, f, P, r, and i have the most significant effects on both roughness and hardness. Ball or tip burnishing leads to the consolidation of the surface layers of both grades 100C6 and 16NC6 steels by work hardening. For each steel grade and its mechanical treatment, the rational tensile curve has been drawn. Lüdwick's law is used to better plot the work hardening curve. For both grades, a material hardening law is established. For 100C6 steel, these results show a work hardening coefficient and a consolidation rate of 0.513 and 44, respectively, compared to the surface layers processed by turning. When 16NC6 steel is processed, the work hardening coefficient is about 0.29. Hardness tests characterize well the burnished depth. The layer affected by work hardening can reach up to 0.4 mm. Simulation of the tests is of great importance to provide the details at the local scale of the material. Conventional tensile curves provide a satisfactory indication of the toughness of 100C6 and 16NC6 materials. A simulation of the tensile curves revealed good agreement between the experimental and simulation results for both steels.Keywords: 100C6 steel, 16NC6 steel, burnishing, work hardening, roughness, hardness
Procedia PDF Downloads 157424 Enhancing Oscillation Amplitude Response Generated by Vortex Induced Vibrations Through Experimental Identification of Optimum Parameters
Authors: Mohammed F. Alhaddad
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Vortex induced Vibrations (VIV) is a phenomenon that occurs as a result of a flow passing by a bluff body. This phenomenon has been mainly studied to be suppressed to prevent fatigue and instability in offshore platforms. In 2006, some studies were conducted to maximize VIV instead of suppressing it, as these studies claimed that VIV is a potential method of generating energy. The aim of this paper is to identify factors for maximizing oscillation amplitude generated by VIV in order to enhance the energy harnessed through this method. The experimental study in this paper will examine the effect of oscillating cylinder diameter, surface roughness, the location of surface roughness with respect to the centerline of the oscillating cylinder and the velocity on the oscillation amplitude of the used module.Keywords: energy, generation, generating, vibration, vortex.
Procedia PDF Downloads 40423 Selective Laser Melting (SLM) Process and Its Influence on the Machinability of TA6V Alloy
Authors: Rafał Kamiński, Joel Rech, Philippe Bertrand, Christophe Desrayaud
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Titanium alloys are among the most important material in the aircraft industry, due to its low density, high strength, and corrosion resistance. However, these alloys are considered as difficult to machine because they have poor thermal properties and high reactivity with cutting tools. The Selective Laser Melting (SLM) process becomes even more popular through industry since it enables the design of new complex components, that cannot be manufactured by standard processes. However, the high temperature reached during the melting phase as well as the several rapid heating and cooling phases, due to the movement of the laser, induce complex microstructures. These microstructures differ from conventional equiaxed ones obtained by casting+forging. Parts obtained by SLM have to be machined in order calibrate the dimensions and the surface roughness of functional surfaces. The ball milling technique is widely applied to finish complex shapes. However, the machinability of titanium is strongly influenced by the microstructure. So the objective of this work is to investigate the influence of the SLM process, i.e. microstructure, on the machinability of titanium, compared to conventional forming processes. The machinability is analyzed by measuring surface roughness, cutting forces, cutting tool wear for a range of cutting conditions (depth of cut ap, feed per tooth fz, spindle speed N) in accordance with industrial practices.Keywords: ball milling, microstructure, surface roughness, titanium
Procedia PDF Downloads 288422 Morphological and Chemical Characterization of the Surface of Orthopedic Implant Materials
Authors: Bertalan Jillek, Péter Szabó, Judit Kopniczky, István Szabó, Balázs Patczai, Kinga Turzó
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Hip and knee prostheses are one of the most frequently used medical implants, that can significantly improve patients’ quality of life. Long term success and biointegration of these prostheses depend on several factors, like bulk and surface characteristics, construction and biocompatibility of the material. The applied surgical technique, the general health condition and life-quality of the patient are also determinant factors. Medical devices used in orthopedic surgeries have different surfaces depending on their function inside the human body. Surface roughness of these implants determines the interaction with the surrounding tissues. Numerous modifications have been applied in the recent decades to improve a specific property of an implant. Our goal was to compare the surface characteristics of typical implant materials used in orthopedic surgery and traumatology. Morphological and chemical structure of Vortex plate anodized titanium, cemented THR (total hip replacement) stem high nitrogen REX steel (SS), uncemented THR stem and cup titanium (Ti) alloy with titanium plasma spray coating (TPS), cemented cup and uncemented acetabular liner HXL and UHMWPE and TKR (total knee replacement) femoral component CoCrMo alloy (Sanatmetal Ltd, Hungary) discs were examined. Visualization and elemental analysis were made by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Surface roughness was determined by atomic force microscopy (AFM) and profilometry. SEM and AFM revealed the morphological and roughness features of the examined materials. TPS Ti presented the highest Ra value (25 ± 2 μm, followed by CoCrMo alloy (535 ± 19 nm), Ti (227 ± 15 nm) and stainless steel (170 ± 11 nm). The roughness of the HXL and UHMWPE surfaces was in the same range, 147 ± 13 nm and 144 ± 15 nm, respectively. EDS confirmed typical elements on the investigated prosthesis materials: Vortex plate Ti (Ti, O, P); TPS Ti (Ti, O, Al); SS (Fe, Cr, Ni, C) CoCrMo (Co, Cr, Mo), HXL (C, Al, Ni) and UHMWPE (C, Al). The results indicate that the surface of prosthesis materials have significantly different features and the applied investigation methods are suitable for their characterization. Contact angle measurements and in vitro cell culture testing are further planned to test their surface energy characteristics and biocompatibility.Keywords: morphology, PE, roughness, titanium
Procedia PDF Downloads 117421 Numerical Investigation of the Bio-fouling Roughness Effect on Tidal Turbine
Authors: O. Afshar
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Unlike other renewable energy sources, tidal current energy is an extremely reliable, predictable and continuous energy source as the current pattern and speed can be predicted throughout the year. A key concern associated with tidal turbines is their long-term reliability when operating in the hostile marine environment. Bio-fouling changes the physical shape and roughness of turbine components, hence altering the overall turbine performance. This paper seeks to employ Computational Fluid Dynamics (CFD) method to quantify the effects of this problem based on the obtained flow field information. The simulation is carried out on a NACA 63-618 aerofoil. The Reynolds Averaged Navier-Stokes (RANS) equations with Shear Stress Transport (SST) turbulent model are used to simulate the flow around the model. Different levels of fouling are studied on 2D aerofoil surface with quantified fouling height and density. In terms of lift and drag coefficient results, numerical results show good agreement with the experiment which was carried out in wind tunnel. Numerical results of research indicate that an increase in fouling thickness causes an increase in drag coefficient and a reduction in lift coefficient. Moreover, pressure gradient gradually becomes adverse as height of fouling increases. In addition, result by turbulent kinetic energy contour reveals it increases with fouling height and it extends into wake due to flow separation.Keywords: tidal energy, lift coefficient, drag coefficient, roughness
Procedia PDF Downloads 375420 Synthesis and Tribological Properties of the Al-Cr-N/MoS₂ Self-Lubricating Coatings by Hybrid Magnetron Sputtering
Authors: Tie-Gang Wang, De-Qiang Meng, Yan-Mei Liu
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Ternary AlCrN coatings were widely used to prolong cutting tool life because of their high hardness and excellent abrasion resistance. However, the friction between the workpiece and cutter surface was increased remarkably during machining difficult-to-cut materials (such as superalloy, titanium, etc.). As a result, a lot of cutting heat was generated and cutting tool life was shortened. In this work, an appropriate amount of solid lubricant MoS₂ was added into the AlCrN coating to reduce the friction between the tool and the workpiece. A series of Al-Cr-N/MoS₂ self-lubricating coatings with different MoS₂ contents were prepared by high power impulse magnetron sputtering (HiPIMS) and pulsed direct current magnetron sputtering (Pulsed DC) compound system. The MoS₂ content in the coatings was changed by adjusting the sputtering power of the MoS₂ target. The composition, structure and mechanical properties of the Al-Cr-N/MoS2 coatings were systematically evaluated by energy dispersive spectrometer, scanning electron microscopy, X-ray photoelectron spectroscopy, X-ray diffractometer, nano-indenter tester, scratch tester, and ball-on-disk tribometer. The results indicated the lubricant content played an important role in the coating properties. As the sputtering power of the MoS₂ target was 0.1 kW, the coating possessed the highest hardness 14.1GPa, the highest critical load 44.8 N, and the lowest wear rate 4.4×10−3μm2/N.Keywords: self-lubricating coating, Al-Cr-N/MoS₂ coating, wear rate, friction coefficient
Procedia PDF Downloads 120419 Cutting Tool-Life Test of Ceramic Insert for Engine Sleeve
Authors: Adam Janásek, Marek Pagáč
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The article is looking for an experimental determination of tool life tests for ceramic cutting inserts. Mentioned experimental determination should provide an added information about cutting process. The mechanism of tool wear, cutting temperature in machining, quality machined surface and machining process itself is the information, which are important for whole manufacturing process. Mainly, the roughness plays very important role in determining how a real object will interact with its environment. The main aim was to determine the number of machined inserts, tool life and micro-geometry, as well. On the basis of previous tests the tool-wear was measured at constant cutting parameter which is more typical for high volume manufacturing processes.Keywords: ceramic, insert, machining, surface roughness, tool-life, tool-wear
Procedia PDF Downloads 485418 Chemometric Determination of the Geographical Origin of Milk Samples in Malaysia
Authors: Shima Behkami, Nor Shahirul Umirah Idris, Sharifuddin Md. Zain, Kah Hin Low, Mehrdad Gholami, Nima A. Behkami, Ahmad Firdaus Kamaruddin
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In this work, Inductively Coupled Plasma Mass Spectrometry (ICP-MS), Isotopic Ratio Mass Spectrometry (IRMS) and Ultrasound Milko Tester were used to study milk samples obtained from various geographical locations in Malaysia. ICP-MS was used to determine the concentration of trace elements in milk, water and soil samples obtained from seven dairy farms at different geographical locations in peninsular Malaysia. IRMS was used to analyze the milk samples for isotopic ratios of δ13C, 15N and 18O. Nutritional parameters in the milk samples were determined using an ultrasound milko tester. Data obtained from these measurements were evaluated by Principal Component Analysis (PCA) and Hierarchical Analysis (HA) as a preliminary step in determining geographical origin of these milk samples. It is observed that the isotopic ratios and a number of the nutritional parameters are responsible for the discrimination of the samples. It was also observed that it is possible to determine the geographical origin of these milk samples solely by the isotopic ratios of δ13C, 15N and 18O. The accuracy of the geographical discrimination is demonstrated when several milk samples from a milk factory taken from one of the regions under study were appropriately assigned to the correct PCA cluster.Keywords: inductively coupled plasma mass spectroscopy ICP-MS, isotope ratio mass spectroscopy IRMS, ultrasound, principal component analysis, hierarchical analysis, geographical origin, milk
Procedia PDF Downloads 358417 Multi Response Optimization in Drilling Al6063/SiC/15% Metal Matrix Composite
Authors: Hari Singh, Abhishek Kamboj, Sudhir Kumar
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This investigation proposes a grey-based Taguchi method to solve the multi-response problems. The grey-based Taguchi method is based on the Taguchi’s design of experimental method, and adopts Grey Relational Analysis (GRA) to transfer multi-response problems into single-response problems. In this investigation, an attempt has been made to optimize the drilling process parameters considering weighted output response characteristics using grey relational analysis. The output response characteristics considered are surface roughness, burr height and hole diameter error under the experimental conditions of cutting speed, feed rate, step angle, and cutting environment. The drilling experiments were conducted using L27 orthogonal array. A combination of orthogonal array, design of experiments and grey relational analysis was used to ascertain best possible drilling process parameters that give minimum surface roughness, burr height and hole diameter error. The results reveal that combination of Taguchi design of experiment and grey relational analysis improves surface quality of drilled hole.Keywords: metal matrix composite, drilling, optimization, step drill, surface roughness, burr height, hole diameter error
Procedia PDF Downloads 308416 Annealing Process Study at Galvanizing Line: Characterization and Implication Inherent to Lead Entrainment
Authors: Marcelo Franzkowiak Stahlschmidt
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This paper discusses the experiments carried out based on the wire drawing process analysis and later annealing on lead furnace on a galvanizing line. Using Design of Experiments methodology, the aim of this work is to understand the occurrence of lead entrainment originating from the annealed wires in order to decrease this problem. Wire samples were collected from wire drawing machines and galvanizing line and submitted to surface roughness analysis and its implications on lead drag out based on wire speed, wire diameter, lead bath temperature, thermal capacity of the lead kettle, wire surface condition, wire roughness and wire superficial cleanliness. Proposals to decrease lead drag out were made in order to increase wire drawing machines and galvanizing line performance.Keywords: wire drawing process, galvanizing, heat treatment, lead
Procedia PDF Downloads 633415 Effects of Alkaline Pretreatment Parameters on the Corrosion Resistance and Wettability of Magnesium Implant
Authors: Mahtab Assadian, Mohd Hasbullah Idris, Mostafa Rezazadeh Shirdar, Mohammad Mahdi Taheri, S. Izman
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Corrosion behaviour and surface roughness of magnesium substrate were investigated after NaOH pretreatment in different concentrations (1, 5, and 10 molar) and duration of (10 min, 30 min, 1 h, 3 h, 6 h and 24 h). Creation of Mg(OH)2 barrier layer after pretreatment enhanced corrostion resistance as well as wettability of substrate surface. Characterization including Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD) was conducted to detect the existence of this barrier layer. Surface roughness and wettability of substrate was evaluated using atomic force microscopy (AFM) and contact angle measurement respectively. It is found that magnesium treated by 1M NaOH for 30 min reveals higher corrosion resistance and lower water contact angle of substrate surface. In addition, this investigation indicates that pH value of SBF solution is strongly influenced by different time and concentration of alkaline pretreatment.Keywords: magnesium, NaOH pretreatment, corrosion resistance, wettability
Procedia PDF Downloads 951414 Uncovering Hidden Bugs: An Exploratory Approach
Authors: Sagar Jitendra Mahendrakar
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Exploratory testing is a dynamic and adaptable method of software quality assurance that is frequently praised for its ability to find hidden flaws and improve the overall quality of the product. Instead of using preset test cases, exploratory testing allows testers to explore the software application dynamically. This is in contrast to scripted testing methodologies, which primarily rely on tester intuition, creativity, and adaptability. There are several tools and techniques that can aid testers in the exploratory testing process which we will be discussing in this talk.Tests of this kind are able to find bugs of this kind that are harder to find during structured testing or that other testing methods may have overlooked.The purpose of this abstract is to examine the nature and importance of exploratory testing in modern software development methods. It explores the fundamental ideas of exploratory testing, highlighting the value of domain knowledge and tester experience in spotting possible problems that may escape the notice of traditional testing methodologies. Throughout the software development lifecycle, exploratory testing promotes quick feedback loops and continuous improvement by giving testers the ability to make decisions in real time based on their observations. This abstract also clarifies the unique features of exploratory testing, like its non-linearity and capacity to replicate user behavior in real-world settings. Testers can find intricate bugs, usability problems, and edge cases in software through impromptu exploration that might go undetected. Exploratory testing's flexible and iterative structure fits in well with agile and DevOps processes, allowing for a quicker time to market without sacrificing the quality of the final product.Keywords: exploratory, testing, automation, quality
Procedia PDF Downloads 37